Directorate General of Employment & Training COURSE CURRICULA IN THE AREA / SECTOR OF

Advanced Modules

“PROCESS PLANT MAINTENANCE”
FOR UPGRADATION OF
ITI’s into

CENTRE OF EXCELLENCE

INDEX UPGRADATION OF ITI’s INTO CENTRE OF EXCELLENCE SECTOR: PROCESS PLANT MAINTENANCE ADVANCE TRAINING (2nd Year) ADVANCE MODULE PPMAM-01 PPMAM-02 PPMAM-03 NAME OF THE ADVANCE MODULE Operator Chemical Plant Operation & Maintenance of Boiler & Steam turbine Mechanical Maintenance of Process Plant DURATION Space Required IN WEEKS Sq. 24 Weeks 100 24 Weeks 100 24 Weeks 100 . mt.

instructor qualifications . The training will be provided in three parts as given below: ♦ Training in Basic skill areas for a period of one year. Guidelines for Training in Advanced modules A minimum of three modules would be essentially needed . If it is felt that available modules for which the course curricula has been developed at National Level are not sufficient to cater to the needs of local industry in a particular state. The training programme will have multi-entry and multi-exit provisions as given below: • • trainee can opt to go to the labour market after completing broad based basic training of one year duration or after completing advanced module/s. multi-entry and multi-exit provisions would enable a trainee to take admission for advanced/ additional advanced /specialized module as per his/her need . ♦ Training in Advanced modules of six months duration after Broad based basic Training(BBBT) ♦ Testing & Certification both for the Broad Based Basic Training & Advanced Module Training during subsequent six months will be conducted under the aegis of NCVT . Qualification of instructor of the various modules of “Processes Plant Maintenance ” sector are attached herewith. Said certificate will have recognization from NCVT ♦ As per the recommendations of the EFC. Space requirement. They may develop suitable module(s) accordingly in consultations with the industry clearly indicating tool & equipment list . These Centres will be providing multiskill training to meet the skill requirement of particular sector of industry with their active involvement in all aspects of training. duration etc will be designed in consultations with the IMC/local industry). so as to ensure that all the 96 trainees are accommodated in the three modules may be selected in consultation with IMC for which in two shifts . space norms etc. & forward the same to DGE&T for seeking approval of NCVT. A trainee at a time can opt only for one Advanced Module . Admission Criteria. States are free to select module as per need in consultation with industry . .Upgradation of ITIs into Centres of ExcellenceBroad guidelines for implementation of Advanced Module of Sector “Processes Plant Maintenance”. The trade testing & certification for specialized module will be done jointly by the State Government & Industry. Training in the shop floor should constitute alteast 2540% of the curriculum. ♦ Training in specialized modules mainly by the industry (The course curricula.

. requirement In Weeks THE MODULE Completed BBBT in Processes 100 sq m 24 weeks Degree in Chemical Engg with PPMA Operator Plant Maintenance (PPM) OR minimum three years M-01 Chemical NTC/NAC in relevant trade teaching/industrial experience in th Plant OR Diploma in relevant trade relevant field PPMA M-02 PPMA M-03 Operation & Maintenance of Boiler & Steam turbine Mechanical Maintenance of Process Plant Completed BBBT in PPM OR NTC/NAC in relevant trade OR Diploma in relevant trade Completed BBBT in PPM OR NTC/NAC in relevant trade OR Diploma in relevant trade OR Diploma in Chemical Engineering with min five years teaching/industrial experience in th relevant field OR HNTC in Related area with min five years teaching/industrial experience in th relevant field . could be offered admission in Advanced Module . MODULE Admission criteria Space Duration Qualification/Status Of Instruc NAME OF NO.Admission to Advanced Module for the graduates of ITI in related trades: There is a provision for lateral entry for graduates of ITIs (NTC /NAC passed outs from conventional system ) of the related trades subject to availability of seats in Advanced Module. Trades of conventional system mentioned against each advanced module in the enclosed statement.

.Prabhu Nath Lecturer (Chemical) 12.Members of the Trade committee for Advance Module of Process Plant Maintenance 1. Kashipur (U. S.Mayank Agrawal Principal 4.. I. S. I.Nand Kishore Instructor (Machinist) 7. T. Singh General Manager (Tech. I. S.) 11. M. S. & D. Nagar) Govt.. Kashipur (U.Manoj Kathuria Asstt. Chief Engineer 9. Nagar) The Co-operative Sugar Mill Ltd.. S. Nagar) Dabur India Ltd. Nagar) . Engineer 13. Nagar) India Glycols Ltd. Kashipur (U. S. C.S. Foreman 14.R. N. Kashipur (U. Kashipur (U.. S.A. S.Abhishek Kumar Dy.. S.) 6. I. Kashipur (U... Bazpur (U. Nagar) Govt. Nagar) India Glycols Ltd. S. P. Nagar) Govt.Dixit Dy. Gupta Manager Maintenance 5. Nagar) Govt. Polytechnic.Ram Iqbal Instrument Sup. I. T. S.Manav Sharma Dy.Shailendra Singh Asstt. S. Nagar) Banwari Paper Mills Ltd. S.Abhinav Thapaliyal Lecturer (Mech.. Kashipur (U. Pant Nagar (U. Nagar) U. Sugar Mill Ltd.Raj Deep Sharma Instructor (Electronic) 8. Haldi (U... Gen. Kashipur (U.Y. I. Nagar) Govt. Manager (Tech. S. Polytechnic. T. Nagar) D. Kashipur (U. Manager 10. S. Gen.) 2. Kashi Vishwanath Steels Ltd.Lokendra Singh Mech. Kashipur (U. Manager 3. Nagar) Kashi Vishwanath Steels Ltd. Kashipur (U.

MSDS. (2) To study of electric Cell using series and parallel connections. (5) Determination of young’s modules by Searle’s apparatus. Role of maintenance mechanic in the chemical Indus-tires. Velocity ratio & % efficiency of simple machine. 1 1 Duration – 24 Weeks Theoretical 3 Importance of safety & general precautions observed In the workshop. 2 Physics (1) 3 4 5 To study triangular and parallelogram of force with the help of mechanical board. Rules pertaining facilities available in the institute medical library and gymkhana. (1)To study of Ohm’s Law and Kirchoff’s Law about current and Voltage. (3) Determination of specific resistance using Wheat stone’s bridge. Objectives procedure apparatus required explanation & calculation involved in the experiments. (4) Verification of Faraday’s Ist Law of electrolysis. Objectives procedure apparatus required explanation & calculation involved in the experiments. Course contents. Awareness of First aid. (4) Determination of acceleration due to gravity by simple pendulum. (2) Determination of efficient of static friction using inclined plan. Objectives procedure apparatus required explanation & calculation involved in the experiments. Practical 2 Introduction to safety equipment and their uses etc. (5) Determination of mechanical equivalent of heat using electrical method. fire fighting equipments & hydrant system. (3) Determination of rotation constant of optically active substance by polarimeter. Objectives procedure apparatus required explanation & calculation involved in the experiments. (3) Determination of mechanical advantage. (1)Determination of coefficient opf expansion of solid and liquid. (2) Determination of co-efficient of thermal conductivity of metal rod. Chemistry Separation of mixture by distillation Preparation of following (a) Soap (b) Nitrobenzene (c) Aniline (d) Copper sulphate (e) Ferrous ammonium & sulphate To study the allotropic forms of sulphur. PPEs. duration.Syllabus for the trade of Advance Module PPMAM – 1 Operator Chemical Plant Week No. 7 8 To study of properties of mixture (Fe+S) and compound(Fes) Objectives procedure apparatus required explanation & calculation involved in the experiments. Objectives procedure apparatus required explanation & calculation involved in the . 6 Objectives procedure apparatus required explanation & calculation involved in the experiments.

(1) Installation of venturimeter orifice meter and Rota meter. (2) Top driven centrifuge (3) Ball mill (4) Blake jaw crusher (1) To carry out sieve analysis with sieve shaker. Calibration of Bi-metallic Calibration 0fBourdon tube pressure gauges. valve. Use and maintenance of lagging materials such as glass wool. To calculate overall heat transfer co-efficient for a cell and tube heat exchange. To Determine Reynolds’s number at different velocities. .Temperature. Procedure of installing venturimeter orifice and rotameter precautions to be observed. Qualitative analysis (Inorganic) (Simple with out interfering radicals). Lagging materials. Sketches of the equipment. types and uses. Determine friction losses in a straight pipe fitting. Calibration of resistance thermocouple. (2) Determination of viscosity of liquids by viscometer. shooting and precautions to be observed during operation of the equipments. 12 13 14 15 16 17 18 19 20 21 22 23 24 Volumetric analysis. Separation of a liquid mixture by distillation using Packed tower. Finding rate of drawing curve by tray drier. 10 11 To study the corrosion of metal. Objectives procedure apparatus required explanation & calculation involved in the experiments. (2) Operation of a mixture settler.9 To study action of pure and salt water on metal and alloys. (1) Manometers Calibration of mercury in glass thermometer. Flooding velocity experiment using a packed tower made of glass. Experiment on a level measurement Operation of (1) Plate and frame fitter press. Objectives procedure apparatus required explanation & calculation involved in the experiments. Objectives procedure apparatus required explanation & calculation involved in the experiments. Units of pressure. Objectives procedure apparatus required explanation & calculation involved in the experiments. experiments. (3) Operation of a spray extraction tower. To find rate of evaporation of vertical tube of evaporator. Procedure of conducting experiments calculation and precautions to be observed sketch of the equipment. Procedure of installing venturimeter orifice and rotameter precautions to be observed Procedure of installing venturimeter orifice and rotameter precautions to be observed Procedure of installing venturimeter orifice and rotameter precautions to be observed Procedure of installing venturimeter orifice and rotameter precautions to be observed Procedure of installing venturimeter orifice and rotameter precautions to be observed Procedure of installing venturimeter orifice and rotameter precautions to be observed Procedure of installing venturimeter orifice and rotameter precautions to be observed Construction. To study action of acids and bases on metals alloys. measurements of pressure by different methods. thermocol etc. its units and different methods of measurements. trouble. Determination of flash point. principle.

Thermometers : (i) 0 to 11 C (ii) 0 to 36 C (iii) 0 to 250 C Polarimeter with monochromatic light Abbe refractometer Fulfrish Refractometer Equipment to study Kirchoff’s law and electro chemical equivalent Potentiometer Wheatstone’s bridge Resistances centre zero Galvanometer Quantity 3 01 01 01 02 01 01 01 01 01 01 01 01 01 01 02 01 01 01 01 01 04 01 01 01 01 set 01 set 03 sets 3 pieces 3 pieces 6 pieces 2 pieces 6 pieces 03 06 06 6 sets 3 sets 2 sets 1 set 1 set 2 sets 01 01 02 sets 02 sets 02 sets 2 sets 2 sets 2 sets 4 sets 2 dozen 1 dozen 1 dozen 2 sets 2 sets 2 sets 1 set 2 sets 2 sets 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 . Salorimeter for determining ‘Soules’ Mechanic equivalent of heat and specific heat. Screw jack inclined plane with roller or trolley. Apparatus for measurement of thermal conductivity of good and bad conductors. pulleys or pulley blocks for first. second and third system of pulleys) Different types of levers Instrument for determining ‘g’ (simple pendulum) Barometer Altimeter Searle’s apparatus for young’s module Nicolson Hydrometer with glass jar Wet and dry bulb thermometer Apparatus for measurement specific heat of solid and liquid (Regnaults Apparatus) Apparatus for measurement of co-efficient of expansion (thermal) of solid and liquid. weights etc Simple machines (wheel and axel).LIST OF TOOLS AND EQUIPMENT: ATTENDANT OPERATOR (CHEMICAL PLANT) Sr No 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 Particulars 2 For Unit Operation Laboratory Venturimeter Orificemeter Rotameter Centrifugal pumps – 2 Nos Gear pump Reynolds experiment equipment Shell and tube heat exchanger Boiler Vertical tube evaporator Packed distillation column Packed tower of glass for flooding velocity experiment Plate and frame filter press Top – driven centrifuge Rotary vacuum filter Tray drier Hammer Mill Ball Mill Black jaw crusher Mixer-settler type extractor Spray extraction tower Viscometer Lobe blower for filter press Weighing machine Multistage compressor fitted with inter-coolers and after coolers Sieve shaker and sieves For Physics Laboratory Physical balance (with weight box) Chemical balance (with weigh box) Viscometer (a) CS Wald Viscometer (b) Redwood viscometer th (c) Stop watch(1/10 Second) (d) Thermostatic bath Stalagnometer Travelling microscope Specific gravity bottle Pyknometer Mechanical board for testing triangle and parallelogram of forces including all accessories Spirit level Inclined plane with pulley. pan.

Daniell cell. Acidic cell. Alkali cell with variable resistance Multimeter Battery eliminator Diode valve Triod valve 0 Electric dry oven 200 c 0 Furnace 1100 c. head accumulator. Weston cell.ABC. CO2. Water bath electrically heated Microscopes Refrigerator 200 lit FURNITURE Instructor table 1200x760mm Instructor chair with arm Steel stool 300x300x450mm Discussion table 3000x1200x760mm Steel almirah 1980x900x450mm Steel rack 6 shelves Steel lockers 8 holes Fire extinguishers foam.DCP.Water CO2 Fire buckets on stand Artificial respiration chart First aid box Black board with stand Student table Working bench size 2000 x 1200 x1000 mm leclanche cell. 1 set 1 set 2 sets 2 sets 02 04 sets 04 1 1 2 3 1 02 02 16 02 06 05 06 04 08 04 01 01 16 04 .31 32 33 34 35 36 37 38 39 40 41 42 1 2 3 4 5 6 7 8 9 10 11 12 13 14 pH meter Charger for battery accumulator 12 volt hand operated Dynamo.

Firing and raising. Boiler Auxiliary Plant. Wet steam saturated steam. elementary knowledge of Boiler drum construction and development and drum internals. Difference between box type header and sectional header. peat. Clarificulators precipitators. beadle valve. etc. condensate handling. steam valve etc. (Boiler) Internal pressure versus stress. Operation and reading of gauge glass etc. convection in liquids. charging of steam and water line. heat transfer from condensing vapors – Boiler circulation and Radiation. steam and blow down in Boilers – precautions to be taken – procedure to be . Elementary principles of combustion and methods of firing different fuels I n boilers. Coal/Oil/Gas) feeding mechanism including adjustment of flow of coal. cornish boiler. Pre and post chlorination system. filters. Blow down valves. . by pass valve. induced draft fans etc including starting. Grate drive and draft regulation for proper combustion. escape of heat. Types of boilers. locomotive boilers. Check valve. chemical dosing etc.Feed water temperature Elementary furnace design – water circulation. latest heat super heat. Advantages of water tube boilers – Over fire tube boilers and bent tube boilers. Description and use of safety valves. Waste heat Boilers and Electric Boilers. Steam Generator. Lancashire boiler. Ash fusion – analysis of the gases. Economic boiler. size of coal and storage of coal. Types of pulverized fuel burners and their control function dof each component of the burner – purpose of primary and secondary air supply methods of transporting pulverized fuel from coal mills to PRACTICAL THEORY 2 3 Operation of fuel (i. steam quality. Heat Transmission: Methods of heat transfer – conduction . Properties of coal – coal preparation and cleaning. liquid and gaseous Solid fuels – coal. super heated steam and their properties. Types of water walls used for furnace and their purpose. 5 Reading and control of steam pressure and steam flow. Boiling point. reheat and total heat. Level control during the emergency operations and use of blow down valves. Reactivation of I on exchanges etc. mountings and accessories used on Boilers.. Operation of fans and blowers like forced draft fans. Use and advantage of televised viewers. combination stop and check valves.transmission of heat through boiler plate and composite walls as well pipe coverings. chain grate and spreader stoker etc.e. Boiler mountings and fittings. over straight tube boilers. lagging. for drum water level and furnace flame. Different types of drum water level gauges and flame indicators. traps etc. Control of super heat and reheat temperature. 4 Normal level control in Boilers. sensible heat. Industrial fuels: Solid. water tube boilers. fusible plugs. Air supply and effects of excess and in sufficient primary and secondary air o n combustion. The product of combustion specific heat of gases. stopping capacity adjustment etc. check valves. 6 Operation of water softener equipment including feed water softener. Use of steam table and entropy chart. temperature and pressure relations. its heating and power properties. stream distribution. 7 Correct use of various types of cocks. stop valve. Use and types of baffles. surface area etc. re-heater. convection – natural and forced.Syllabus for Advance Module PPMAM – 2 Operations and Maintenance of Boiler & Steam Turbine WEEK NO. Gate valve. Effects of high temperature o n boiler steel. Burners and Firing. Fire tube boilers. vertical tubular boiler. Steam preventing. Operation of super heater and re-heater. Chemical re-action and factors affecting combustion such as temperature. 1 Operation of various types of valves. Boiler metallurgy. Oxidation and deterioration of coal in storage. Use of mechanical stoker. gauge glasses (mounted and remote type) draught pressure gauges. lignite. Principles of steam and application in Modern Boilers. Steam.

Gas firing system. Chemical cleaning of boiler. Knowledge of Indian boilers Act and rules. Importance of furnace purging an d how it is achieved. study of typical oil burners and purpose of each component. mechanical atomization of oil.observed before starting. Isolating Boiler for cleaning and inspection. Purpose of balance drum and of pump waiming line and speed control. Advantage and disadvantage of two general types of De-super heater.glow down – cleaning fires – banking up fires – cleaning heating surface – case of refractories – carbon losses clinker formation – difference between the use pulverized fuels in boilers and firing on grates. 8 Operation of boiler feed pumps – starting and stopping. Methods of hand and mechanical firing water level. Periodical inspection of Boilers – preparation of boilers for testing – Hydraulic test and steam test. Conditioning of steam and condensate cycle. their advantages over other boilers. hardness etc. Different types of super heaters and their function – Location of super heaters in high temperature and high pressure boilers.. Knowledge of modern packages types boilers and automatic boilers. Testing the correctness of gauge glass and cocks by blowing through them. Offering boiler for hydraulic test and open inspection. 11 12 Correct method of firing and combustion control for prevention of smoke. carry over and caustic gauging. firing and when raising steam. horizontal front firing. Soot Blowers. Water Treatment. In feed water – total dissolved solids – methods of purification – use of Deacrators – priming and foaming – scale formation and corrosion. Purpose and general application of De-super heaters. Constructional details of multistage pump. Causes and remedy of fires in coal burners pipes. priming. Detection of false water level and knowledge of alarm devices. Importance of silica in high pressure Boilers and hw it is controlled.D. Re-heater and De-Super heaters. Method of regulating feed water to boiler. Loss due to escape of combustible gases. alkalinity. Methods of soot blowing and cleaning boiler furnace dur9ing operation. . Importance of drains and vents in super heaters. types of oil burners in sue. Types of oil iquition torches – their function and use. 10 Periodic cleaning and filling the boiler with demineraled or condensate for prevention of scale or other deposits on heating surfaces. Replacement of gauge glass. Grate or stocker failures and fuel oil pump failure. Purpose and types of soot blowers. effects and preventions of furnace explosives. Object of feed water treatment – water analysis water of high pressure boilers. including emergency operation. etc. single down shot and double down shot firing etc. Observation of easing a safety valve. Use of re-circulation line and balance chamber. Precautions to be taken before entering or allowing persons to enter a boiler which is connected to another boiler on the steam. Different types of feed water pump s. Boiler Testing. Boiler Inspection.D. or F. 13 14 Priming of Boiler – the danger of water logging steam pipes and precautions to be observed in runn9ing. Arrangements of burner for tangential firing. Effects of other suspended matter such as oil. soot. Different types.. loss due to escape of solid combustible matter with ash. Precautionary measures taken while soot blowing. softening and demineraliser plant. Description and use of spark ignitors and oil swebs of oil torches. Effects of temperature on super heater tubes. Impurities in water and their harmful effects. Checking and correctness of pressure gauge. Purpose of balance chamber. Boiler safety precautions. Losses due to incomplete combustion. 9 Internal conditioning of Boiler water by checking the TDS and alkalinity by blow down to prevent sealing. Safety precautions to be adopted in cases of fires causes. Adjustment of safety valves for correct blowing – pressure. Stocking and boiler operation. fan failure. I. Methods of controlling super heat temperature of steam. leak off and recirculation line. Injection of oil steam. Super Heater. 15 burners. Efficiency of Boiler (Overall and thermal). Emergency operations explosion hazards feed pumps failure. Requirement of a super heater. Feed Water Regulator and boiler feed water pumps. Fixed and Retarding types and their use. Use of blow down cock or valve. Description and use of bailes type of feed water regulation valve and purpose of by-pass valve in the system.

Governing mechanism and regulating systems both hydrodynamic and mechanical system: Principal of governing. delaval curties. 18 & 19 Study. low oil pressure. tangential and radial. lubrication system. Operation of steam pressure reducing station and H. over speed governor. pressure compounding. mixed pressures. Study of steam cylinder. reduction gear. Adjustment of high steam and low water safety valve. bearing etc. speed limit governor and emergency shut off devices.avoiding it. Double or multiple velocity stages only. Types of construction: horizontal or vertical. cylinders. critical speed damage due to unbalance of rotating parts.condensing turbines. remedies. steam flow. disc. surface condenser. coupling. air leakage. Study of turbine-construction of different parts. vibration at critical speeds. Use of spark ignitors and oil pumps for oil torches.starting an condensing plant. diaphragms rotor blades. shutting down.grinding and adjusting cooks and valve etc. heat carried away by moisture formed from Hydrogen. 2-Service and steam conditions: high pressure. noncondensing. condenser tube leakage. Study of feed water and steam cycle. Turbine troubles and remedies: Vibration of shaft. stability and sensitivity of governors. Operation and adjustment of turbine governor. Division of flow: single. Study of Boiler Act/ Rules 1923 Steam turbine-fundamental principals. by pass station. steady load operation. Failure of 23 Turbine troubles and remedies-study of abnormalities during operation and remedical measures. emergency operations. loss due to radiation and other losses – summarized neat account. condensing and non. Reaction and velocity stages compounding. steam chest. diaphragms. impulse and reaction.water flow. Turbine plant auxiliary: condensers including air ejectors.P. Chimney loss. changing of gland packings. Direction of flow: axial. sequence of operations. governors. Turbine plant operation: general instruction for starting and stopping a steam turbine. discs. glands. internal defects of material. effect of load changes. speed limit governors. reteau. Turning gear. pressures compounding and velocity compounding. constant water level control starting a condensing plant and stopping it. running up turbines from cold and warm and hot conditions. glands. discs. double. reaction stages only. exhaust steam turbine. over speed governors. jet condenser function and construction. bearing. back pressures and pass out machines compounding. According to – 1-Blading or nozzle arrangement impulse reaction and impulse reaction. conversion of heat energy in a steam turbine. pressure regulators. by-pass governing. coupling. discs. loss of vacuum. examples of impulsive and reactive forces. stopping the condensing plant and other auxiliaries. pressure stages only. blades. defects in glands and bearing. thrust balancing. hot bearing etc. Knowledge of different methods of fixing tubes by expending with ferrules. air leakage detection. velocity compounding. care to be taken when removing and applying load on turbo-alternators. Troubles. semi-doubles. Care and precautions to prevent loss of vacuum. isolation for maintenance. simple features of construction and functions of nozzles. . oil relay. Classification of steam turbine. steam chest. pressure and velocity stages. rotors. compound oil relay. such as loss of vacuum. failure due to faulty machining of rotor. method of running up to speed necessity of slow and uniform heating. The trainee must get a through practical idea of manual remote control of governors 20 & 21 22 Turbine plant operation. . method of working of synchronizing governor. nozzle and throttle governing.L. emergency shut off governors.P. care to be taken when removing and applying load to turn-alternators. stopping a turbine . causes and remedy. their meanings. Renewal of fuseable plus. different types. routes care and inspection during normal operation. zeely parsons systems. critical speed avoiding.types. Nomenclature and parts of a turbine. vibration-their causes and remedies 24 Condensers. causes of loss of vacuum. protective devices etc.. 3-Kinds of stage: single. their construction and method of working. blade. starting a steam turbine from cold condition.16 17 Cleaning of oil torches.

their causes and remedies.air leakage. Function and use of evaporators. drain collars and feed heaters. different method of priming. Cooling water system. corrosion and erosion of turbine blades. starting ejectors. care and maintenance of running pumps. putting the pumps on load. care and maintenance. sequence of operation. condenser cleaning methods. Pumps-centrifugal and reciprocating. coupling. checking up of blades. Atmospheric relief valve and others safety devices. starting a centrifugal pump. stopping it. operations. Reheat and regenerative system. diaphragms distortion. alignment of turbine and alternator rotors. . Air ejectors.different types steam hydraulic. Compressors. starting an ejector in conjunction with a condensing plant. putting them into operation and taking them out of operation. maintenance of proper feed water temperature.

20.12.15.11.23. 24x26 Torque wrench Tap set B S W Die set B S W Box spanner socket set 12.7 mm square drive hexagonal sockets set of size 10.33.15.16. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Particulars 2 Measuring tape 3 meter Inside spring caliper 200 mm Outside spring caliper 200 mm Ball pin Hammer – 200 gm Fix spanner 23 mm set 9 spanner Ring spanner 6 to 23 mm Chisel cold flat 20x150 mm Steal scale 300 mm engineering Try square 200 mm Screw driver 300 mm Centre punch 100 mm x 100 mm Scriber 150 mm Bradawl 200 mm Odd leg caliper spring type 200 mm Out side spring caliper 400 mm Inside spring caliper 400 mm Ball pin hammer 400 gm Flat chisel cold 25 x 200 mm Cross cut chisel 150 mm Sledge hammer 2 kg Cross pin hammer 400 gm Mallet Teflon hammer Vernier caliper 200 mm digital type Vernier caliper 150 mm digital type Micrometer 0-25 mm Depth meter 0-300 mm Slip gauge set Feeler gauge leaf type 26 blades eng.List of Tools and Equipments of Operation & Maintenance of Boiler & Steam Turbine Sr.29.24. 17.14. 21.18.34 with accessories Anvil big size Surface plate 400x400 mm ‘V’ Block Hack saw frame adjustable 300 mm Grease gun Oil cane 500 ml Screw Driver 400 mm Screw Driver 300 mm Try square 300 mm Tap set metric Quantity 3 16 16 16 16 16 16 16 16 16 16 16 16 16 16 02 02 04 02 02 01 02 02 01 01 01 01 01 01 02 01 01 01 02 02 02 08 04 08 08 04 08 04 04 04 04 04 04 04 02 each 02 each 01 01 01 02 01 01 02 08 02 02 02 02 02 01 .18.32.26.19.22 mm Ring spanner 25x28.16.28.14.13.30.250 mm Half round file rough – 250 mm Round file smooth – 200 mm Round file Smooth – 200 mm Triangular file – 150 mm Square file – 200 mm Needle file set Allen key 12. 22.27. & metric Radius gauge leaf type 1to 15 mm Digi matic thickness gauge Universal Bevel protector Pipe wrench 200 mm Pipe wrench 300 mm Adjustable wrench 250 mm Combination pliers 200 mm Long nose pliers 200 mm Flat file bastard 250 mm Flat file smooth 250 mm Flat file rough cut 250 mm Flat file rough cut 300 mm Half round file smooth .

pressure safety valve. chimney. with DCS/PLC based control panel IBR water tube boiler trainer model Steam turbine driven with the help above steam boiler with all accessories general and safety devices with DCS/PLC based control panel Stream turbine trainer model Pressure safety valve 12 kg/ cm² Steam traps of different kinds Gauge glass Oil torches of different types Pressure gauge 20 kg/ cm² Temperature gauge 300º C Vacuum gauge Boiler tube cleaning machine with accessories Hydraulic pump with pressure gauge cap. 20 kg/ cm² Water softening plant required for above boiler with all accessories FURNITURE Instructor chair with arm Instructor Table size 1200 x 760 x 760 mm with 3 drawers Steel stool size 450 x 300 x 300 mm Discussion table size 3000 x 1200 x 760 mm Steel almirah size 1980 x 450 x 1200 mm Steel racks size 2400 x 1500 x 450 mm Steel racks size 760 x 1500 x 450 mm Book shelf Black board with stand Steel locker containing 10 cell Fire extinguisher Fire buckets with stand First aid box Artificial respiration chart Working bench size 3000 x 1500 x 1000 mm 01 04 01 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 01 01 01 01 01 each 02 01 each 02 02 02 01 01 01 02 02 20 02 06 02 06 01 01 02 02 02 01 01 02 .65 66 1 Die set metric Bench vice 150 mm General Machinery IBR fire tube boiler of capacity 4 ton pressure 8 kg/cm² with all IBR accessories and general safety devices required to operate it like ID fan. 10 kl. FD fan. fuel tank cap. burner. pre -heater. fuel pump. feed pumps.

dismantling and assembling of centrifugal compressors and its accessories & safety switches. gate. Construction. tube replacement. Principle of Water ring vacuum pumps etc. types of refrigerants their usages. Types of impellers according to construction and material. dismantling and assembling of gear pumps with its accessories Construction. Study and principle of positive displacement compressors – reciprocating. Construction. couplings and joints and chain pulley blocks Overhauling and maintenance of gearboxes. Fixing and dismantling of bearings with the help of different types of attachments. study and types of centrifugal pumps. Construction and operation of different types of valves – Ball. couplings and joints. types of safety devices etc. gasket cutting. Construction. gear. refrigerant compressor and its accessories & safety switches. Types of gaskets with their use. 5 6 7 8 to 10 11 12& 13 14 to 15 16 & 17 18 & 19 20 & 21 22 23 24 . twin and lobe etc. Assembling and opening of pipe lines having different types of joints like flange. plate type. Principle of refrigeration. Construction and maintenance of refrigeration plant with its equipments and safety devices.Syllabus for Advance Module PPMAM -3 Mechanical maintenance of Process Plant Weeks Week 1 1 to 4 Duration – 24 Practical 2 Construction. non return valve. choke removal. gear. Study of different types of bearings and their uses. diaphragm & needle. Study and principle of different types of valves and their usages according to their handling. lubrication of bearings. dismantling and assembling of different types of heat exchangers. glove. Study and principle of positive displacement pumps like reciprocating. Principle of air conditioning system. Study and principle of positive displacement pumps like reciprocating. vane pumps etc. chains. types of safety devices etc. Use according to type of material. Construction. types of refrigerants their usages. Use according to type of material. weld etc. chains. dismantling and assembling of reciprocating compressor – air. screw. Operation and maintenance of types of belts. Construction and maintenance of air conditioning plant with its equipments and safety devices. dismantling and assembling of centrifugal pumps (Single & Multistage) with gland and mechanical seal and its accessories. Study of types of belts. dismantling and assembling of vacuum pumps its accessories. Study of pipe material with according to different types of fluids and their joints. dismantling and assembling of reciprocating pumps with its accessories Construction. Study of heat exchangers – tube and shell type. vane pumps etc. chain pulley blocks s Study of different types reduction speed gear boxes. Study and principle of centrifugal type compressors and its accessories. Theory 3 Principle of centrifugal force.

21.18.17.32.11.14.13.15. 18. 23.28. & metric Radius gauge leaf type 1to 15 mm Digi matic thickness gauge Universal Bevel protector Pipe wrench 200 mm Pipe wrench 300 mm Adjustable wrench 250 mm Combination pliers 200 mm Long nose pliers 200 mm Flat file bastard 250 mm Flat file smooth 250 mm Flat file rough cut 250 mm Flat file rough cut 300 mm Half round file smooth .List of Tools and Equipments for Mechanical Maintenance of Process Plant Sr 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Particulars 2 Measuring tape 3 meter Inside spring caliper 200 mm Outside spring caliper 200 mm Ball pin Hammer – 200 gm Fix spanner 23 mm set 9 spanner Ring spanner 6 to 23 mm Chisel cold flat 20x150 mm Steal scale 300 mm engineering Try square 200 mm Screw driver 300 mm Centre punch 100 mm x 100 mm Scriber 150 mm Bradawl 200 mm Odd leg caliper spring type 200 mm Out side spring caliper 400 mm Inside spring caliper 400 mm Ball pin hammer 400 gm Flat chisel cold 25 x 200 mm Cross cut chisel 150 mm Sledge hammer 2 kg Cross pin hammer 400 gm Mallet Teflon hammer Vernier caliper 200 mm digital type Vernier caliper 150 mm digital type Micrometer 0-25 mm Depth meter 0-300 mm Slip gauge set Feeler gauge leaf type 26 blades eng. 24x26 Torque wrench Tap set B S W Die set B S W Box spanner socket set 12.14.7 mm square drive hexagonal sockets set of size 10.33.34 with accessories Anvil big size Surface plate 400x400 mm ‘V’ Block Hack saw frame adjustable 300 mm Grease gun Oil cane 500 ml Screw Driver 400 mm Screw Driver 300 mm Try square 300 mm Tap set metric Die set metric Bench vice 150 mm Quantity 3 16 16 16 16 16 16 16 16 16 16 16 16 16 16 02 02 04 02 02 01 02 02 01 01 01 01 01 01 02 01 01 01 02 02 02 08 04 08 08 04 08 04 04 04 04 04 04 04 02 each 02 each 01 01 01 02 01 01 02 08 02 02 02 02 02 01 01 08 .30. 24.16.19.26.29.27.15.22 mm Ring spanner 25x28.250 mm Half round file rough – 250 mm Round file smooth – 200 mm Round file Smooth – 200 mm Triangular file – 150 mm Square file – 200 mm Needle file set Allen key 12.20.12.16.22.

S. 6110. 1”. no of tubes 24. dia 1” Four pass straight tube type heat exchanger with M. Cap. 150 mm with rubber bushes Tyre coupling size 150 mm Spider type coupling 75 mm.S. with suitable ISI motor Single stage air compressor with all accessories with suitable ISI motor Single stage double acting refrigerant compressors with safety devices with suitable ISI motor Centrifugal compressor with all accessories with suitable ISI motor S. Cap. gate valve 2” & 4” C.2 m³/hr with suitable ISI motor Gland type four stage centrifugal pump semi open impeller Dis. globe valve 3” Non return valve ½”.1m³/hr with suitable ISI motor Mechanical seal type centrifugal pump with open impeller Dis. shell size dia 12”. 450 mm with all accessories FURNITURE Instructor chair with arm Instructor Table size 1200 x 760 x 760 mm with 3 drawers Steel stool size 450 x 300 x 300 mm Discussion table size 3000 x 1200 x 760 mm Steel almirah size 1980 x 450 x 1200 mm Steel racks size 2400 x 1500 x 450 mm 02 02 02 01 02 01 02 01 01 01 01 01 04 04 each 02 each 02 02 each 02 02 02 01 01 01 01 05 each 04 each 02 01 each 01 each 02 each 02 each 01 each 02 02 each 02 01 01 meter 01 01 01 01 01 01 01 02 01 01 01 20 meter 04 01 01 01 01 02 02 20 02 06 02 . Code size 12 mm.3 m³/hr with suitable ISI motor Reciprocating type vacuum pump Dis. Needle valve 1½” Two pass cast steal U tube type heat exchanger with M. Cap. 6212. Cap. no of tubes 16. 20 mm geared with all accessories All geared shaping machine cap.3 m³/hr with suitable ISI motor Water ring type vacuum pump Dis. shell size dia 10”.S.S. dia ¾” Six pass straight tube type heat exchanger with M. 75 mm & 100 mm Bearing puller Ball bearing 6004.S. safety devices etc.S. dia ½” S. Cap. 25 mm.4 m³/hr with suitable ISI motor Internal gear pump (Spur gear ) Dis.S. plate type heat exchanger having four plates size 36” Choke removal pump with accessories Flanges as per I. no of tubes 36. Cap.S. Ball valve one piece construction ½” & two piece construction 2” C. 19 mm.3 m³/hr with suitable ISI motor Two stage double acting Air Compressor with all accessories like receiver. 6420 Roller bearing of different sizes Taper roller bearing Needle roller bearing Flange coupling size 100 mm.4 m³/hr with suitable ISI motor External gear pump (Herring bone gears) Dis.I. 4” Diaphragm valve 1” S. 50 mm Collar type flanges size 50 mm.67 68 69 70 Pipe vice 100 mm Internal circlip plier straight 150 mm External circlip plier spring type 150 mm Water pump plier slip joint 250 mm 02 04 04 04 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1 2 3 4 5 6 General Machinery Gland type centrifugal pump with closed impeller Dis.3 m³/hr with suitable ISI motor Stainless steal centrifugal pump Dis. ¾”. Wire rope dia 12 mm D shackles Root blower All geared Lathe machine admit between centres 1500 mm with all accessories Drill machine cap. Ball valve single piece construction 1” C. shell size dia 16”. 100 mm Knuckle joint size 6” Kotter joint Different types of chains Gear Box reduction type ratio 1:4 rack & pinion Gear Box reduction type ratio 1:10 rack & pinion Lapping plate along with lapping paste of different grades Hydraulic pump with pressure gauge upto 20 kg/cm² Power hacksaw machine of blade size 600 mm Pedestal Grinder with coarse and fine grinding wheels size 300 mm Angle hand grinding machine Strainer Y-type Strainer bucket type Spring loaded safety valve capacity 5 kg/cm² Chain pulley block one tonne G. Cap.S.S. Cap.

7 8 9 10 11 12 13 14 15 16 Steel racks size 760 x 1500 x 450 mm Book shelf Black board with stand Steel locker containing 10 cell Fire extinguisher Fire buckets with stand First aid box Artificial respiration chart Working bench size 3000 x 1500 x 1000 mm Steel bench size 2000 x 450 x 450 mm 06 01 01 03 02 02 01 01 03 06 .

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